Lenze g500 Series User manual

.V8i Ä.V8iä
Mounting Instructions EN
g500 S130 ... S660 | 130 Nm ... 660 Nm
Shaft−mounted helical gearboxes / shaft−mounted
helical gearboxes with servo motor


Please read these instructions before you start working!
Follow the enclosed safety instructions.
0Abb. 0Tab. 0

Contents i
3
Lenze ¯ MA 12.0018 ¯ 2.0
1 About this documentation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Document history 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Conventions used 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Terminology used 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Notes used 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Safety instructions 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 General safety instructions for drive components 6. . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Application as directed 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Foreseeable misuse 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Residual hazards 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 Disposal 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Product description 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Important notes 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Identification 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.1 Nameplate 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Transport weights 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Mechanical installation 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Important notes 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Transport equipment for gearboxes 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Preparation 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Mounting 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.1 General information about the assembly of drive systems 16. . . . . . . . . . .
4.4.2 Mounting the gearboxes 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.3 Mounting of g500 short/servo adapters with clamping connection 16. . .
4.4.4 Mounting of motors on gearboxes with mounting flange and
flexible coupling (drive−end version N) 21. . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.5 Attachment of gearboxes with hollow shafts and keyway 23. . . . . . . . . . .
4.4.6 Mounting the shrink disc with a rotating cover 25. . . . . . . . . . . . . . . . . . . .
4.4.7 Mounting the fixed cover 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.8 Mounting the hoseproof hollow shaft cover 29. . . . . . . . . . . . . . . . . . . . . .
4.4.9 Foot mounting 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.10 Gearboxes with breathers 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Electrical connection 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Commissioning and operation 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Important notes 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Before switching on 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 During operation 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contentsi
4 Lenze ¯ MA 12.0018 ¯ 2.0
6 Maintenance 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Important notes 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Maintenance intervals 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Maintenance operations 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 Repair 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Troubleshooting and fault elimination 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About this documentation
Document history
1
5
Lenze ¯ MA 12.0018 ¯ 2.0
1 About this documentation
Contents
¯ This documentation serves for safety−relevant operations on and with the
gearboxes. It contains safety instructions which must be observed.
¯ All personnel working on and with the gearboxes must have the documentation
available during the work and observe the information and notes relevant for
them.
¯ The documentation must always be complete and in a perfectly readable state.
Target group
This documentation is directed at qualified skilled personnel according to IEC 60364.
Qualified skilled personnel are persons who have the required qualifications to carry out
all activities involved in installing, mounting, commissioning, and operating the
product.
Tip!
Information and tools concerning the Lenze products can be found in the
download area at
www.lenze.com
1.1 Document history
Material number Version Description
13478512 1.0 12/2014 TD09 First edition for the pilot series
.V8i 2.0 04/2017 TD09 New chapter: Servo adapter
1.2 Conventions used
This documentation uses the following conventions to distinguish different types of
information:
Type of information Writing Example/notes
Spelling of numbers
Decimal Normal spelling Example: 1234
Decimal separator Point The decimal point is always used.
For example: 1234.56
Icons
Page reference Reference to another page with additional
information
For instance: 16 = see page 16
Documentation reference Reference to another documentation with additional
information
Example: EDKxxx = see EDKxxx documentation
Wildcard Wildcard for options, selection data

About this documentation
Terminology used
1
6 Lenze ¯ MA 12.0018 ¯ 2.0
1.3 Terminology used
Term In the following text used for
Gearboxes Gearboxes of the g500 product family
Drive system Drive systems with g500 gearboxes and other Lenze drive
components
1.4 Notes used
The following pictographs and signal words are used in this documentation to indicate
dangers and important information:
Safety instructions
Layout of the safety instructions:
Danger!
(characterises the type and severity of danger)
Note
(describes the danger and gives information about how to prevent
dangerous situations)
Pictograph and signal word Meaning
Danger!
Danger of personal injury through dangerous electrical voltage
Reference to an imminent danger that may result in death or
serious personal injury if the corresponding measures are not taken.
Danger!
Danger of personal injury through a general source of danger
Reference to an imminent danger that may result in death or
serious personal injury if the corresponding measures are not taken.
Stop!
Danger of property damage
Reference to a possible danger that may result in property damage
if the corresponding measures are not taken.
Application notes
Pictograph and signal word Meaning
Note! Important note to ensure trouble−free operation
Tip! Useful tip for easy handling
Reference to another document

Safety instructions
General safety instructions for drive components
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Lenze ¯ MA 12.0018 ¯ 2.0
2 Safety instructions
2.1 General safety instructions for drive components
Danger!
Disregarding the following basic safety measures may lead to severe
personal injury and damage to material assets!
¯ Store in dry, low−vibration environment without aggressive atmosphere; if
possible in the manufacturer’s packaging.
–Protect against dust and impacts.
–Observe the climatic conditions according to the technical data, catalogue.
¯ Lenze drive and automation components ...
... must only be used as intended.
... must never be commissioned despite noticeable damage.
... must never be technically changed.
... must never be commissioned in an incompletely mounted state.
... must never be operated without the required covers.
... may have live, moving or rotary parts during and after operation − corresponding
to their type of protection. Surfaces may be hot.
... must not be operated with large vibrations.
... must not be operated in the frequency range of a plant or the drive system.
¯ All specifications of the corresponding enclosed documentation must be
observed.
This is vital for safe and trouble−free operation and for achieving the specified
product features.
¯ Only qualified skilled personnel are permitted to work with or on Lenze drive and
automation components.
According to IEC 60364 or CENELEC HD 384, these are persons ...
... who are familiar with the installation, assembly, commissioning and operation of
the product,
... possess the appropriate qualifications for their work,
... and are acquainted with and can apply all the accident prevent regulations,
directives and laws applicable at the place of use.
Transport, storage
¯ Transport and storage in a dry, low−vibration environment without aggressive
atmosphere; preferably in the packaging provided by the manufacturer.
–Protect against dust and impacts.
–Observe climatic conditions according to the technical data.
¯ Use load carrying equipment for transport! (16)

Safety instructions
General safety instructions for drive components
2
8 Lenze ¯ MA 12.0018 ¯ 2.0
If you do not install the motor immediately, ensure proper storage conditions.
¯ Up to one year:
–Shafts and uncoated surfaces are delivered in a protected against rust status.
Aftertreatment is required where the corrosion protection has been damaged.
–Remove the plug for motors with condensation drain holes (special version).
¯ More than one year, up to two years:
–Apply a long−term corrosion preventive (e.g. Anticorit BW 366 from the Fuchs
company) to the shafts and uncoated surfaces before storing the motor away.
Corrosion protection
Lenze offers paints with different resistance characteristics for drive systems. Since the
resistance may be reduced when the paint coat is damaged, defects in paint work (e.g.
through transport or assembly) must be removed professionally to reach the required
corrosion resistance.
Mechanical installation
¯ Provide for careful handling and avoid mechanical overload. During handling
neither bend components, nor change the insulation distances.
Electrical installation
¯ Carry out the electrical installation according to the relevant regulations (e. g.
cable cross−sections, fusing, connection to the PE conductor). Additional notes are
included in the documentation.
¯ The Instructions contain notes concerning wiring according to EMC regulations
(shielding, earthing, filters and cable routing). The compliance with limit values
required by the EMC legislation is the responsibility of the manufacturer of the
machine or system.
Warning: The inverters are automation components which can be used in industrial
environment according to EN 61000−6−4. These products may cause radio
interference in residential areas. If this happens, the operator may need to take
appropriate action.
¯ Only plug in or remove pluggable terminals in the deenergised state!
Commissioning
¯ If required, you have to equip the system with additional monitoring and
protective devices in accordance with the respective valid safety regulations (e. g.
law on technical equipment, regulations for the prevention of accidents).
¯ Before commissioning remove transport locking devices and keep them for later
transports.

Safety instructions
Application as directed
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Lenze ¯ MA 12.0018 ¯ 2.0
2.2 Application as directed
Low−voltage machines are not household appliances, but are intended as components
that are only applied for re−use for industrial or professional purposes in terms of
IEC/EN 61000−3−2.
They meet the requirements of the Low−Voltage Directive 2006/95/EC and the
harmonised standards of the IEC/EN60034 series.
It is permissible to use low−voltage machines with IP23 protection or less outdoors only
if special protective measures are taken.
Do not use the integrated brakes as fail−safe brakes. It cannot be ruled out that the
braking torque will be reduced due to disruptive factors that cannot be influenced.
¯ Drives
–... must only be operated under the operating conditions and power limits
specified in this documentation.
–... comply with the protection requirements of the EC Low−Voltage Directive.
Any other use shall be deemed inappropriate!
2.3 Foreseeable misuse
¯ Do not operate the motors
–... in explosion−protected areas
–... in aggressive environments (acid, gas, vapour, dust, oil)
–... in water
–... in radiation environments
Note!
Increased surface and corrosion protection can be achieved by using
adapted coating systems.

Safety instructions
Residual hazards
2
10 Lenze ¯ MA 12.0018 ¯ 2.0
2.4 Residual hazards
Protection of persons
¯ Risk of burns!
–Hot surfaces up to 140 °C during operation! Provide protection against contact.
¯ High−frequency voltages can be capacitively transferred to the motor housing
through the inverter supply.
–Earth motor housing carefully.
¯ Risk of injury due to rotating shaft!
–Before working on the motor ensure that the motor is at standstill.
¯ Danger of unintentional starting or electrical shocks!
–Connections must only be made when the equipment is deenergised and the
motor is at standstill.
–Installed brakes are no fail−safe brakes.
¯ Dangerous voltages at the power terminals, even if the plug is removed: residual
voltage >60 V!
Motor protection
¯ Installed thermal detectors do not offer full protection to the machine.
–If required, limit the maximum current, parameterise the inverter so that it will
be switched off after some seconds of operation with I > IN, especially if there is
the danger of blocking.
–Installed overload protection does not prevent an overload under any
conditions.
¯ Installed brakes are no fail−safe brakes.
–The torque can be reduced due to disruptive factors that cannot be influenced,
e.g. by ingressing oil due to a defect shaft sealing ring on the A side.
¯ Fuses are no motor protection.
–Use current−dependent motor protection switches at an average operating
frequency.
–Use installed thermal detectors at a high operating frequency.
¯ Excessive torques lead to a break of the motor shaft or demagnetisation.
–The maximum torques according to catalogue must not be exceeded.
¯ Lateral forces from the motor shaft may occur.
–Align shafts of motor and driving machine exactly to each other.
¯ If deviations from normal operation occur, e.g. increased temperature, noise,
vibration, determine the cause and, if necessary, contact the manufacturer. If in
doubt, switch off the motor.
¯ Design with plug:
–Never disconnect plug when energised! Otherwise, the plug can be destroyed.
–Switch off power supply and inhibit controller prior to disconnecting the plug.

Safety instructions
Disposal
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Lenze ¯ MA 12.0018 ¯ 2.0
Fire protection
¯ Fire hazard
–Prevent contact with flammable substances.
2.5 Disposal
Sort individual parts according to their properties. Dispose of them as specified by the
current national regulations.

Product description
Important notes
3
12 Lenze ¯ MA 12.0018 ¯ 2.0
3 Product description
3.1 Important notes
¯ The most important technical data is given on the nameplate.
¯ The product catalogues contain further technical data.
3.2 Identification
Mounting position (A−F) and position of system modules (1−6)
Hollow shaft: 0 Without foot: 0
Solid shaft: 6 Foot: 3, 4, 5
Hollow shaft with shrink disc: 1, 6 Connector / terminal box: 2, 3, 4, 5
Flange: 6

Product description
Nameplate
3
13
Lenze ¯ MA 12.0018 ¯ 2.0
3.2.1 Nameplate
Gearbox
1
318 6
5.2 5.3 5.4
7.1 7.2
5.1 10.2 10.3
11
10.1 20.1
L
DE
27
38
Asynchronous and synchronous servo motors
L
9
15
11
24
1
10.2
9
8.1
12
5.5
5.6
5.7
5.8
5.9
14.2
5.2
5.10
14.1
5.4 5.3
22
14.3
27
16.6
18
8.2 8.3
10.3

Product description
Nameplate
3
14 Lenze ¯ MA 12.0018 ¯ 2.0
Pos. Contents
1Manufacturer / production location
2Type of motor / standard
3Gearbox type
4Motor type
5Technical data
5.1 Ratio
5.2 Rated torque
5.3 Rated speed
5.4 Rated frequency
5.5 Rated voltage
5.6 Rated current
5.7 Maximum current
5.8 Rated power [kW]
5.9 Rated power [HP]
5.10 Continuous standstill torque
6Mounting position / position of the system blocks
7Lubricant details
7.1 Lubricant amount
7.2 Lubricant type
8Brake data
8.1 Type
8.2 AC/DC brake voltage
8.3 Braking torque, electrical power input
9For feedback / pulse encoder or resolver data
10 Production data
10.1 Order number
10.2 Material number
10.3 Serial number
11 Bar code
12 Motor number
14 Additional motor specifications
14 14.1 Temperature class
14 14.2 Enclosure
14 14.3 Motor protection
16 Rated data for various frequencies
16.6 cos j= motor power factor for MA
Uin [V] = induced voltage for MC
18 Year of manufacture / week of manufacture
20 Customer data
20.1 Additional customer data
21 UL category (e.g. inverter duty motor)
22 C86 = motor code for inverter parameterisation (code 0086)
27 Permissible ambient temperature (e.g. Ta £40°C)
38 Load capacity (specified if c<1.0)

Product description
Transport weights
3
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Lenze ¯ MA 12.0018 ¯ 2.0
3.3 Transport weights
Gearbox with motor type MCA
Gearbox Motor frame size
Code Type 10 13 14 17
G50BS113 g500−S130 < 15 < 20 < 30
G50BS122 g500−S220 < 20 < 25 < 30 < 40
G50BS140 g500−S400 < 20 < 30 < 35 < 40
G50BS166 g500−S660 < 25 < 35 < 40 < 45
Tab. 1 Weights in kg
Gearbox with motor type MCS
Gearbox Motor frame size
Code Type 06 09 12 14
G50BS113 g500−S130 < 10 < 20 < 25
G50BS122 g500−S220 < 15 < 20 < 25 < 45
G50BS140 g500−S400 < 20 < 25 < 30 < 45
G50BS166 g500−S660 < 25 < 30 < 35 < 50
Tab. 2 Weights in kg

Mechanical installation
Important notes
4
16 Lenze ¯ MA 12.0018 ¯ 2.0
4 Mechanical installation
4.1 Important notes
Before transport
¯ check that all component parts are safely mounted;
¯ check that all component parts with a loose fastening are secured or removed;
¯ tighten all transport aids (eye bolts or support plates).
Use an appropriate means of transport and lifting equipment! (16)
Stop!
Danger by toppling or falling loads!
Observe payloads!
¯ The payload of the hoists and load handling devices must at least
correspond to the weight of the load, for weights see the catalogue.
¯ Secure the load so that it will not topple or fall down.
¯ Walk under suspended loads prohibited!
4.2 Transport equipment for gearboxes
Danger!
The motors attached to the gearbox are partially equipped with eyebolts.
They are exclusively determined for mounting/dismounting the motor to
the gearbox and must not be used for the complete geared motor!
Stop!
Observe load carrying capacity!
Standing beneath floating loads is prohibited!
g500−S130 ... S660
Fig. 1 Ear of the complete drive system

Mechanical installation
Preparation
General information about the assembly of drive systems
4
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Lenze ¯ MA 12.0018 ¯ 2.0
4.3 Preparation
Note!
Thoroughly remove anticorrosion agents from output shafts and flange
faces.
4.4 Mounting
4.4.1 General information about the assembly of drive systems
Stop!
The lubricant fill quantity of the gearboxes is matched to the mounting
position. The mounting position indicated on the nameplate must be
observed to avoid damage to the gearbox.
4.4.2 Mounting the gearboxes
Draw the transmission elements onto the output shaft only by using the centering
thread.
Stop!
Shocks and blows to the shafts damage the roller bearings.
4.4.3 Mounting of g500 short/servo adapters with clamping connection
Important notes
¯ The transmission is made in a force−fitting manner via a clamping connection.
Greases, oils and other substances which reduce the friction factor reduce the
torque to be transmitted which is why these should be avoided in the connection.
¯ The motor shaft diameter must be designed with fit k6.
¯ The motor centering diameter must be designed with fit j6.
¯ With regard to smooth running tolerance of the motor shaft, concentricity of the
centering and axial runout of the mounting flange, the motor must fulfil the
requirements according to DIN 42955 R (reference values for smooth running <
0.025 mm; axial runout and concentricity < 0.05 mm).

Mechanical installation
Mounting of g500 short/servo adapters with clamping connection
Mounting the gearboxes
4
18 Lenze ¯ MA 12.0018 ¯ 2.0
4
5
Fig. 2 Measurement of the surfaces of smooth running, axial runout and concentricity
4 Motor flange
5 Centering
Preparation
¯ Ensure standstill of the drive system and prevent any machine movement.
¯ The drive system must have cooled down.
¯ The motor must be deenergised.
Note!
Lenze recommends the use of smooth motor shafts without slots!
1. Check:
¯ If the drill depth in the hollow drive shaft is sufficient for the motor shaft.
–For this purpose, compare the drill depth from the flange face with the distance
of motor shaft front side to the motor flange.
¯ Check of the motor shaft journal, the hollow shaft bore of the gearbox drive shaft,
the flange faces and the centering at the motor and gearbox for damages.
In the event of irregularities, parts have to be reworked or sorted out.

Mechanical installation
Mounting of g500 short/servo adapters with clamping connection
Mounting the gearboxes
4
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Lenze ¯ MA 12.0018 ¯ 2.0
2. Cleaning:
¯ Thoroughly clean and degrease hollow shaft bore and motor shaft journal, Fig. 3.
A3
2
1
Fig. 3 Shaft surfaces
1 Gearbox degrease
2 Bell housing
3 Motor
Mounting
1. Install the gearbox vertically so that the drive end is on top and securely fasten it.
2. Locate the position of the mounting hole and remove the plug (5) from the bell
housing (2) and keep it!
1
2
5
Fig. 4 Removing the plug from the bell housing
1 Gearbox 5 Plug
2 Bell housing
3. Align the slots of the gearbox drive hollow shaft and the clamping ring to each
other and to the mounting hole (Fig. 5).

Mechanical installation
Mounting of g500 short/servo adapters with clamping connection
Mounting the gearboxes
4
20 Lenze ¯ MA 12.0018 ¯ 2.0
8
7
2
Fig. 5 Assignment: Motor shaft, clamping ring and mounting hole
2 Bell housing 7 Clamping ring
8 Terminal screw
4. Afterwards, insert the wrench (9) into the terminal screw (8) of the clamping ring
(7) and leave it there (Fig. 6). The terminal screw (8) must only be tightened to
such a degree that the clamping ring (7) does not move but the shaft is not
tightened yet!
1.
3.
2.
1
9
3
Fig. 6 Mounting of motor and gearbox
1 Gearbox 9 Wrench
3 Motor
Stop!
If the motor shaft is provided with a keyway, align the motor shaft in
such a way that the keyway is located opposite to the terminal screw.